HEIDENHAIN

DR. JOHANNES HEIDENHAIN GmbH is constantly working on further developments of its TNC Controls. It is therefore possible that details of your Control may differ slightly from those described herein. If that is the case please order a suitably revised issue of the Service Manual. Copying/Duplication This manual is provided subject to the condition that no part of it shall be reproduced in any form or by any means without our prior consent in writing. Issue: 01/87

Diagnosis for fault-finding Flow diagrams for fault location Fault diagnosis for the complete installation Use of the integrated supervision system Testing of the VDU and associated circuitry Testing of the mains supply and the Power Supply Testing of the measuring systems and wiring
Burn-In Test

1. Use of the Service Manual TNC 151 In order to determine the fault condition on an NC machine, a fundamental knowledge of the machine and the drives is necessary, as well a a knowledge of their interaction with the Control and measuring system. In addition, improper use such as incorrect NC programming or incorrect of the Control, selection of machine parameters can lead to the occurrence Further information in this respect can of fault conditions. be found in: .TNC 151 OPERATING MANUAL .TNC 151 MOUNTING INSTRUCTIONS AND INTERFACE CIRCUIT CONTROLMACHINE .TNC 151 PLC-DESCRIPTION

The TNC 151 Service Manual is used for the diagnosis, localisation and remedying of faults on TNC controlled machines. In chapter 2, Fault Diagnosis, a set of flowcharts enables the user to pinpoint the source of a fault from its symptoms _ An integrated built-in supervision system and a Burn-In Test Program specifically developed for testing the Control can aid in the location of faults. Important guidance for the exchange of entire Controls, individual boards, or software is given in section 3, Exchange Information. Section 4, Additional Information, contains a block diagram of the Control, a wiring diagram for each version of the Control, and a list of machine parameters with permissible entry values.

2. the machine-tool and the measuring system.1
To locate and rectify a fault that has arisen in a TNC installation. ining the complete installation. the procedure for exam2. the HEIDENHAIN TNC 151 Contouring Control includes an extensive integrated supervision system for the avoidance of entry/operator faults and for the recognition and diagnosis of technical defects in the installation (see section 2. In addition.2.
SERVICE Page 3 Section
MANUAL 2/2.1 shows.6).2.2) The Burn-In Test Program can be used as further fault localizing and in the dynamic testing of hardware (see section 2. support in the Control's
. JOHANNES HElDENHAlN GmbH D-8225 Traunreut .1
TNC 153
Fault procedure
Diagnosis for fault-finding
2.HEIDENHAIN
DR.Tel. it is of foremost importance to analyse the behaviour of the system as a whole: that is. in flow diagram form. the TNC Control. (08669) 31-O Kundendienst 2.

.Tel. the machine-tool and the measuring system). (08669)
31-O
SERVICE Page 5 Section
MANUAL 2.3/A..2.2
Use
of
the
integrated
supervision
system
The TNC 151 incorporates an extensive integrated supervision system for the avoidance of operator-errors and the detection and diagnosis of technical faults in the TNC installation (ie the installation comprising the TNC.. The supervision system is made up and software within the TNC... and the TNC is switched on.2
TNC 151
2. JOHANNES HElDENHAlN GmbH
D-8225Traunreut
. or if an will be displayed... Examples of faults are measuring system faults..
.
TNC 151
SYSTEM DEFECTIVE
EMERGENCY Example of operator-error: a) KEY NON-FUNCTIONAL b) ENTRY VALUE INCORRECT
STOP DEFECTIVE POINT
WRONG REFERENCE EMERGENCY
STOP PLC ERROR A/B/C/D EXCEEDED
GROSS POSITIONING Example of fault with TNC internal electronics: a) TNC OPERATING TEMP.K
example of X-MEASURING
fault with measuring SYSTEM DEFECTIVE
system: CHECK SUM ERROR XXOO. cating (in abbreviated form) the of a mixture of hardware operates continuously whilst is detected. If a fault a message operator-error occurs. TNC.Q TNC ELECTRONICS DEFECTIVE O....3/A.K TNC OPERATING
TEMP. after messages is given on page 7.
Flashing ASIS
fault X/Y/Z/4
messages MEAS.. drive faults and faults in the TNC's internal electronics.neluelunnllu
DR. in that faults are shown as flashing displays.
The system distinguishes between what are considered to be harmless errors and serious faults.XXFF
Example of fault GROSS POSITIONING
on machine-tool: ERROR A
The significance pages 8 to 13 A (non-flashing) @key on the A list of error
of
these
fault
messages
is
explained
on
error message can be cleared by pressing the which normal operation may resume. The occurrence of a fault leads to the machine being switched off via the emergency-stop contactor.
ERROR IN PLC PROGRAM A.2. indinature of the problem. The fault must then be rectified before the TNC is switched on again. EXCEEDED b) EXCHANGE BUFFER BATTERY c) TNC ELECTRONICS DEFECTIVE O.

Please note that the TNC has to be switched on when exchanging the buffer batteries. special care should be taken that the polarity is correct (POS-pole of battery outwards). The battery needs to have IEC designation "LR 6" and must be of the leak-proof type. With discharged (or missing) buffer batteries.2. We especially recommend the use of VARTA Alkaline batteries type "4006".Tel. The buffer battery compartment is located behind the screw cover in the lower left-hand corner of the operating panel. When exchanging the batteries.2
Error
message
"MCBA?JGB
BUFFER
BATTBRY"
Particular mention should also be made about the implications of the instruction to exchange the buffer battery: If the dialogue display indicates "EXCHANGE BUFFER BATTERY".HEIDENHAIN
DR. the memory for the machine parameters and for the user-program will be supported only as long as the mains remains switched on. JOHANNES HEIDENHAN GmbH D-8225 Traunreut. the re-entry of the machine parameters and the user-program will be necessary.(08669)31-0
SERVICE Page 6 Section
MANUAL TNC 151 2.
.chanqe (or when the battery is discharged or missing). If a mains failure occurs during a battery.
Use
of
the
integrated
supervision
system. new batteries must be inserted within one week. Continued operation is still possible but the memory contents will become erased in the event of a mains failure.

Tel. or whether it lies elsewhere.DR. JOHANNES D-8225Traunreut Kundendienst
nelueluniillu
HEIDENHNN GmbH .(O8669) 31-O
SERVICE MANUAL TNC 151 Paae 14
Se&ion 2.2. which contains the control circuitry for the Display Unit. in which case it must be returned to DR JOHANNES HEIDENHAIN for repair. in which case the test and repair procedure continues according to section 2. with the asscociated circuitry. This is a possible source of the fault. it is likely to be due to the CLP Processor Board. If the fault still persists then must be due either to bad connections within the TNC (eg on the Connector Board). This can be verified by exchanging the board for one when is known to function correctly.
. or to faults on both the VDU end the CLP Processor Board. Testing of the mains supply end the Power Supply Unit.2. procedure for
Testing
of the VDU and associated
circuitry.3
Testing
of the VDU and associated
circuitry
The first objective is to determine whether the fault is actually with the Display Unit. The Display Units BE 111 and BE 211 are powered by an 11V dc supply from the Power Supply Board.3
2. in which case repairs may be possible without returning the unit. If the fault is not due to a detective power supply.2.4. See the diagram opposite for a logical locating the fault in the system.

2.l.Tel.1
.lZ
* not Signal
used
with
TNC 151 for
the
Fuses plug and test points. (08669) 31-O
SERVICE MANUAL Page 15 Section 2.
6 7 9. and the respective "nominal" and "actual" test voltages under load.2. it may be necessary to test the voltages at various points on the Power Supply Board.10.4
TNC 151
2.4
Testing
of
the
mains
supply
and
the
Power
Supply
Unit
The procedure for testing the Power Supply Unit is shown in the flow diagram on page 16. Test
Fl points
and F2 not on the
used Power
on TNC 151 Supply Board
designations
. As part of that procedure. JOHANNES HEIDENHAJN GmbH D-8225 Traunreut .Blllh
Kundendienst
7 HEIDENHAIN
DR. . The diagram below and the table opposite show the locations of the test points (solder terminals) on the Power Supply Board.

. Where appropriate. order exchange unit.JOHANNES HEIDENHAIN for return.

Defectiw
scannino
head
I
.

the issue of the NC Software can be determined from the NC Software issue number. In this case. Both these numbers are found on the type-plate on the rear of the Control. before exchanging any board. Figs. However. and schematic representations
. It is important to have the correct test program for the type of Control and for the Control's current NC Software issue. inspite tions on the control.6
Burn-111 Test
of there being definite fault condiIn some casee.2. The test program cannot be loaded into the Control if the flashing error message: "TNC ELECTRONICS DEFECTIVE" is present on the VDU. The test program is stored on a digital cassette and can be loaded into the Control via magnetic tape units ME 101 B/ 102 B or ME 101 C/102 C (Program versions 212 902 05/ 212 902 07). 2 to 5 show pictorial of each individual adapter. 1. (TNC with either a standard SE interface or with an external PLC I/O Board) the appropriate adapters must be connected as shown in fig.4). it is advisable to check the output voltage from the Power Supply Unit (see section 2. the faulty board must be determined by exchanging each board in turn until the fault is eliminated.~~lUENllAlN
DR. The type of Control can be determined from the identification number of the unit.
2. JOHANNES D-8225Traunreut Kundendienst HEIDENHAIN GmbH . The test programs are listed on page 20.2. However.2.6 Depending on the type of Control. the Control's electronics can be tested with the help of the Burn-In test program. TO run the Burn-In test program it is neccessary to have a set of Burn-In Test Adapters. This test program is a means of dynamically testing the Control's hardware and can be used not only for duration testing but also for fault diagnosis.Tel. error messages may not be displayed on the VDU.(O8669)31-0
SERVICE MANUAL TNC 151 Page 18 Section 2.

Consequently. to the Control.ME START EXTERNAL DATA INPUT" To complete the data transfer. turn over the cassette and press the START button on the ME unit.
will be displayed on the MU. The VDU will again display the dialogue. by "POWER INTERRUPTED". user-programs already loaded/programmed into the Control will be unaffected by loading the Burn-In test program.
"CODE NUMBER=".
6 Initialization
of ME unit it automatically time the dialogue
3. Prepare the ME unit to down-load the test program to the Control by inserting the appropriate program cassette (see list. when all the data from the first track has been transferred. the following of the Burn-In dialogue will
test program be displayed:
from the NE
"POWERINTERRUPTED EXTERNAL DATA INPUT" If necessary. ries out a memory test.2. the following dialogue will be displayed: "EXCHANGE CASSETTE . Cartape Any
Fig. and then:
2. Control must now be prepared: After applying power to the Control.SERVICE MANUAL TNC
Kundendienst Page 26 section 2.6
151
Loading (Burn-In
the Burn-In test
test
program loaded) (ME 101/102) to the
The necessary code number for reading in the Burn-In program is entered by pressing the following keys: Elas often as necessary to obtain the display:
test
program not already
1. The Burn-In test program occupies both tracks of the cassette tape. During this
“MEMORY
TEST" the dialogue will be replaced
5. blockwise. the MB unit will first rewind the cassette before transmitting the data. The data transfer is then initiated by pressing:
by pres-
E3l
During the loading unit. Upon completion of this test. page 20) and pressing the following buttons:
1’
I-
1
(Errors in entering these numbers can be corrected sing cl CE )4.
. Connect the Magnetic Tape Cassette Unit V-24 socket on the sear of the Control.

2.HEIDENHAIN
DR. by pressing
CONNECTED
Any and
other display the program
implies an error in must be reloaded from
the the
stored cassette. (08669) 31-O Kundendienst
SERVICE MANUAL Page 28 Section 2. JOHANNES HElDENHAlN GmbH D-8225 Traunreut ‘Tel. 17 sec. It is also possible that the system has been warm-booted.
the
dialogue
will
be replaced
"PRESS
NOENT KEY"
IMPORTAIJT Only press
the
key
if you wish to cram the normal operating To restart the Bum-In
the Burn-In test system.
test
program
Under both of to be followed The test Control takes
‘MEMORY
these circumstances in order to restart carry during
the following the Burn-In
procedure is test program: This
will automatically approx. this test. t&t priqramm
program press
and return
to \
. In this situation the buffer batteries will maintain the program in memory until the mains is restored. during the execution of the Bum-In test.6
TNC 151
Re-initialization
of
a previously
loaded
Burn-In
test
program
The
following "EXTERNAL
dialogue UNIT
will
then ?"
be displayed:
The possibility exists that the Burn-In test program has been loaded and then the power removed. which time the dialogue
will Upon by
be displayed completion
of
on the VDU. TEST"
out a memory check.

. . The keys must now be pressed once in a defined sequence. . . . E . the display "REREAD-IN PROGRAM XXXX CHECK SUM ERROR" will from appear on the the ME unit. . OR 2 PC-BOARD ?" external the test. in order that the Control can check that each key is making contact and delivering the correct code to the keyboard interface. . . .. . beginning with the top row. For each correct key-push.2. key. key will following . . . . test program data has nbt been corrupted error is detected. . has been stored the sequential 4. 1. If
the an
The lines of dots represent the individual keys in each of the four keying fields.
an external on the VDU. . each. the sequence is from left to right. by pressing the key
keyboard
be skipped
In the case of a Control designed for PLC I/O Board. the keyboard test will start again from the beginning. cause display the test to be carried will appear on the out. VDU: in which .
the
. .
q
Any other case the .
.HEIDENHAIN
DR. . . VDU. . test has previously been carried out (eq failure). . .
”
2. the following text will following a successful keyboard test: "0. . out
If the keyboard test an error message has error message will be for an interrupt (see
5. "*". . . Beginning "EXTERNAL
of
the
Bum-In
test
initialization procedure of figure must be described 9. and the test
tb ensure that in any way. . (08669) 31-O Kundendienst
SERVICE MANUAL TNC 151 Page 29 Section 2. use with appear out. . ..E . . . .6
Continuation The remainder in conjunction 1. .E .. . . If the keyboard before a power is not displayed. . . . . . . . .. The keying sequence is as follows: top right set of 20 keys =I b) top left set of 10 keys middle left set of 20 keys Cl d) bottom right set of 10 keys In each case. JOHANNES HEIDENHAlN GmbH D-8225 Traunreut ‘Tel. . has previously been carried been stored from an earlier displayed and the program point 7). .
A check is now automticall$ carried out. . page 31
of the initialization with the flow diagram with the display UNIT CONNECTD ?"
which refers to the use of an externai operator must respond by pressing
test
computer. and run. the option of carrying out the test In this case. this will wait
program
must
be reloaded
3. .E
This refers to the number of nected to the Control during with the appropriate numeric
PLC I/O Boards conand must be answered
. . . . If an incorrect code is received. . assuming no errrx message from a previous run. .
If the keyboard test has not already prior to a mains interruption) the this test will now be displayed: "JUMP The OVER KEYBOARD test can TEST ?"
been option
carried out of carrying
(eq. the respective dot on the VUU will be replaced with a. the program jumps into tests (see page 32).

the realigned and
7. the test program can be interrupted by pressing one of a number of keys.
also
possible. SPEED ADJUST: 100" If necessary. JOHANNES HEIDENHAJN GmbH D-8225 Traunreut ‘Tel. initialization
cause restarts routine. interruptions of the program are inhibited.BATTERY TRIGGER OVERRIDE POT ADJUST: 100 SP. and the tightened in the 100% position. to various points in the test procedure. ROT. BATTERY TRIGGER OVERRIDE POT ADJUST: 100 SP.POT. SPEED ADJUST: 100"
. After completion of the initialization. (08669) 31-O
SERVICE MANUAL TNC 151 Page 30 Section 2.6
6. the caps of the knobs securing screws slackened. ROT. These must be adjusted "TEST INT.mlh
Kundendienst
7 HEIDENHAIN
DR. interrupts are enabled to permit jumps. at any time.PCT. Once the interrupts have been enabled.
the
re-boot
isl q
“EXTERNAL
UNIT
CONNECTD
?"
"JUMP
OVBRKBYBOARD
TEST ?"
"0.
OR 2 PC-BOARD
?"
"TEST INT. 8 and 9.
At the beginning of the initialization procedure.
procedure is the on the front panel of to give the display:
Other interrupts the following
are section. The keys:
fbr example.. as System
at various points during shown in figs.2.
these
are
described
in
must knobs
be removed.
1.
The final step of the full initialization calibration of the two potentiometers the Control.

Checks the RAM on the Main Processor
"INPUT/OUTPUT TEST 1. counters etc). face socket. : "INPUT/OUTPUT TEST 1. The following tests are included:
a) Key El "TEST INT. outputs. (08669) 31-O
SERVICE MANUAL TNC 151 Page 32 Section 2. a fault condition will be displayed: eg. f) Key El "TEST STATIC RAM CLP PROCESSOR BOARD" g) Key El "PC INSTRUCT DECODER. repetitively.checks the RAM on the Memory Board.
out the PLC
El (after a short delay) the VDU will display the input tions when only output 0 is being driven high. + by pressing the key site in quick succession.~ INPUT 0 20 40 60 01234567890123456789 01111111111111111111 11111111111 111111111111 1111 'i
El
to the Main
01111111 1111111
Board BURN IN TIME: x.Checks the RAM where the PLC data is held inputs. BATTERY TRIGGER" . This repetitive mode will be indicated by a "1" at input position 31 on the VDU.Ih
7 HEIDENHAIN
DR. JOHANNES HElDENHAlN GmbH D-8225 Traunreut ‘Tel. each output individually. and checking the corresponding able to deduce whether a fault is on an input or an output. check that all test adapters are including the connection to the V-24 intercorrectly connected. Each output is connected to 2 inputs.The check-sums of all EPROMs accessible Processor Board CPU are checked.6
h) Key
Kundendienst
sequential (duration) tests Before starting these tests.2.Front panel potentiometers must be set to 100 2 2% b) Key cl0 "EPROM TEST CPU" .
q
Input 31 is used to monitor a 20 ms monostable pulse generated on the Emergency Off output. PI& BOARD OUTPUT (or input) FAILURE . PC BOARD" (only TNC 151 P) The PLC I/O Board outputs are resistively loaded and connected to the inputs by means of the PC Burn-In Adapter. If a fault is detected (a "0" on an input) the input conditions are displayed on the VDU: eg. By pressing the key can be driven
(markers.x HRS" always a zero
d) Key El "RAMTEST MEMORY BOARD" . the Control is puts. By writing "1"s to the outinputs. This test must not be interrupted by a mains failure e) Key "TEST PC PAM" . To aid in locating an I/O fault. timers. : "MONOFLOPTIME TOO SHORT 2OMS" This pulse can be generated manually by individual PrOoEing of the key cl or. If the duration of this pulses falls outside its tolerance limits.POT. ACCU-FF TEST" The circuitry used for decoding and carrying instructions is tested.
condi-
. cl Key El "RAMTEST CPU BOARD .

POT. INPUTS Subsequent pressing of
Key El "TEST REFERENCE IMPULSE INPUT" . or restarted at any point by pressing the appropriate key. JOHBNNES HEIDENHAIN
D-8225Traunreut
GmbH .
begin-
. Key "TEST TRANSDUCER INPUTS. are used to connect logue outputs X. to the ext. : 'INPUT01234567890123456789
0
20 40 60
ml Key
tc
10000000000000000000 00000000000010000000
00000000000000000000
0001 \ (always a "1") EO. inat three
j)
Key El "TEST V24-INTERFACE" Key El "TEST 3D-SCANNER INTERFACE" . the anapot. IV. the fault message associated with the first fault will be stored. Y. S.Checks the effect of signals system inputs.(eg key 8 to begin with the V. E32 the key n)
"SUPERVISION CIRCUIT .Checks the effect of a signal pulse inputs.24 interface test.Checks the
HANDWHEEL interface
INPUT" to the
HE 310 Handwheel
Unit
This ning
key with
also the
the sequential tests BATTERY TRIGGER".HEIDENHAIN
DR.
This causes a system re-boot. EXE" .
on page key
30.Checks the interface to the
k)
Touch
Probe.Tel.
circuitry
which
moni-
OUTPUT AO. 2/3 pages 22/23).
applied
to
the
reference-
allows high. w.
El successive outputs (in ascending or in descending order with the El be cleared a
order) key
to
be driven
o)
q
applied
to
the
measuring
All
outputs
can
with
the
key Starting the sequential tests The test sequence can be started. 9. (08669) 31-O
SERVICE MANUAL TNC 151 Page 33 Section 2. ANALCG OUTPUT TEST" Five external relays within the TNC 150 A/P Burn-In driven from outputs Al6 . Fault recognition The detection of a fault will be displayed on the VDU. PDT. Z. as explained All fault messages can be cleared with the El causes a restart of test "TEST INT. pu%(see figs.6
-
I I
Kundendienst
eg.) All 15 keys associate $ with the sequential tests act as interrupts to the Burn-In test program.5v
q
Adapter. The test cycle will be halted and the Burn-In Time stops.2.A20.
f) Key SERIAL q "TEST
. in turn. If one or more faults arise during the execution of the Burn-In test program. The stored message can be retrieved at any time by pressing the key
i)
Key "EXT.checks the threshold tors the measuring
TEST" values of the system inputs. The test is made different voltages:
2OhV.

HEIDENHAIN
DR. AMP.Key . Another possible interrupt to the Burn-In test program is by means of the key El With this key the entire played on the VDU. regardless of whether a fault is detected.") . Option 2 means that the test will be run cyclically until such time as a fault is detected.Key
: Battery voltage check ** ("TEST BATTERYVOLTAGE")
in brackets tests are appears on not suitable VDU
0 *
l
text these
for
custmr
ye. To do this.2. seouential tests can also be made to run cyclically.Tel. When one mode OT the other has been selected.
* Bee follaing
l xp1nNtions:
. the VDU will display: "SELECT TEST" The desired test must then be selected with the appropriate key.1OV") of analogne output * ANALDG OUTPUTLINEARITY")
6 .Key 0.6 Calibration Interrupting check of the Anelogue Board ("TRIMMING ROUTINES") the Burn-In test program with the key
Individual test runs Each of the individual.1ov analogne output ** ("DAC + ANALOGOUTPUT+/. : Lrnearity ("DAC +
.Key .Key . JOHANNES HEIOENHAlN GmbH D-8225 Traunreut .Key cl1 : Reference amplifier ("TRANSMISSION BEHAVIOUR REF. 32 STEPS") : DAC performance * ("TRANSMISSION BEHAVIOUR DAC") : +/. the test program must be interrnpted with the key El The VDU will then display: "1 = CYCLIC 2 = STOPAT FAULT" Option 1 means that the test (still to be selected) will be run cyclically. set of ASCII characters can be dis-
Within ted:
the calibration
mode the following
tests
can be selec-
performance * . (08669) 31-O Kundendienst
SERVICE MANUAL TNC 151 Page 34 Section 2.Key
q q q q q
: Analogue output voltage ** ("ANALOGVOLTAGEOUTPUT") : 32-step monotonic DAC * ("MONOTONIYDAC.

JOHANNES HEIDENHAIN GmbH D-8225 Traunreut ‘Tel. the Y key 3 times.: IV
24. 244mV and 2. can be sunned at at each of the analoque outputs (X. (08669) 31-O Kundendienst
SERVICE MANUAL TNC 151 Page 35 Section 2. Y.2. w.s. the X key is pushed 5 times.
the
battery
voltage
is
. S). if eq.44 mV) + (3.4mV.44V respecincrements of 2.4 mV) + ( 1 x 2.t. otherwise a "0" is displayed. IV.HEIDENHAIN
DR. the output voltage should read: (5 x 2.24.44 V) = 2. Using the keys Jl.. output of
The analogue outputs should generate +lOV. and the key once.
q
voltage tively z.6
Key : Analoque output voltaqe The performance of the analoque output circuitry can be checked by connecting a DVM to each of the analoque outputs (eq X-axis: pin 2) and selecting this test.44mV. pinl.5254 V of the output. The polarity can be reversed
Key a: Battery voltage check A "1" will be displayed on the VDU if adequate.1ov q
analogue
output their maximum as in test 2.can be reversed using the key
The polarity
The
output
can be
cleared
using
the
key
Key : +/.x.

EMERGENCY STOP).73 S8. Exchange Information U&e: All inputs/outputs from the TNC 151 Control can only be connected to circuits which have voltages conforming to VDE 5. Do not disconnect or connect plugs under power!
NC machines also need protection and installation safety as required for manually operated machines (e. (08669) 31-O
SERVICE MANUAL TNC 151 Page 36 Section 3
3.g. Before exchanging a Control noted or stored on magnetic the machine parameters tape! should be
.m
u
HEIDENHAIN
D? JOHANNES HEIDENHAIN GmbH D 8225 Traunreut ‘Tel. Their function should be checked during commissioning of the machine and of a new Control.

service is necessary and/or servicing the
1 2
a conductive
work surface
a wristband that provides en electrical connection between person and conductive work surface a cable between that equalizes potential differences conductive work suface and ground
3
. on the left of the serial no. Although MOS ICs are equipped with an input protection diode network. . end work personnel must be properly grounded. The assembly no. tools. instruments. JOHANNES HEIDENHAIN GmbH D-8225 Traunreut ‘Tel. (08669) 31-O
SERVICE MANUAL TNC 151 Page 41 Section 3. The following requirements in the work area must be met: Prior to working with MOS components or with assemblies containing MOS elements.2 Work area requirements The TNC 151 contains sub-assemblies with MOS elements. is impressed on every board.Please observe MOS protection measures when exchanging boards. only. to eliminate the build-up of static charges care must be taken when handling these elements.
A portable "MOS-HANDLING-SET" for field when exchanging the operating software TNC 151:
caution:
. all table coverings.llEllJENllAlN
DR.Exchange boards with the same assembly no.

The connector sockets on the board are coded with coding pins.
j _Insezting the boards: The connectors of the boards is therefore avoided.HEIDENHAIN
DR. which means that the machine parameters and any user-programs will be lost! Before inserting the new Memory Board plug in the relevant EPROMs (EPROM IC-Pll-to IC-P18).
. Press tor Board using the ejector Main Processor When exchanging IC-P19 on the Main Processor
Memory
are coded: incorrect the board firmly into keys tilted inwards.
I . paying particular attention to their correct location and orientation.
Analogue Board Before removing the Analogue/Analogue TTL Board pull off and mark the connector plugs for the measuring system inputs/ square wave signal inputs and the electronic handwheel input.
insertion the Connec-
and CLP Processor Board: these boards insert program CLP Processor Board and IC-P4 Board.(08669)31-0 Kundendienst GmbH
SERVICE MANUAL TNC 151 Page 42 Section 3.
EPROM's IC-P3 and to IC-PlO on the
Board: During the exchange or removal of the Memory Board the buffered RAM will no longer be supplied with voltage. JOHANNES HElDENHAlN D-8225Traunreut. Removing the boards: Press the board ejector keys outwards and pull out the individual board form the top.2
Exchanging the pluggable boards Unscrew the 5 mounting screws and remove the housing cover.Tel.3
.

.Remove connectors J13 (feedrate-override potentiometer) and J14 (spindle-override potentiometer) from the Connector Board.HEIDENHAIN
DR. . .Remove the Keypad Board. .(08669) Kundendienst GmbH 31-O
SERVICE MANUAL TNC 151 Page 43 Section 3.Remove the 7 cross-head fixing screws which secure the Keypad Board to the frontplate.Remove the 6 cross-head fixing screws from the frontplate.Pull off the Keypad connectors. ensure that the keypad connecengaged in their respective sockets.Tilt the frontplate outwards. .2
Exchanging the Keypad Board: . Pl to P8 from the Keypad Board. .Tel. JOHANNES HEIDENHAN D-8225Traunreut.
When rebuilding tors are firmly the LEDs project keypad housing. and that through the corresponding bored holes in the
.Remove the ribbon cable connector PlO from the Keypad Board.
the assembly.

6. .24 connector on the rear of the Control.Unsolder the connectors to the MU socket from the Connector Board (solder terminals 1.Remove the 4 cross-head mounting screws from the rear of the Control (2 screws are found in the connector box).Remove the back wall with the Power Supply Unit and Terminal Board.2
TNC 151
Kundendienst
Exchanging the Power Supply Unit: .5. JOHANNES HEIDENHAIN GmbH D-8225 Traunreut .8. .4. .
Comector Board
‘I
.Ih
7 HEIDENHAIN
DR.Remove the 2 cross-head fixing screws of the V.Remove the voltage supply plug.10).7. Note the colour of the wire connected to each terminal.Tel. from the Connector Board (see diagram). . (08669) 31-O
SERVICE MANUAL Page 44 Section 3. PI.Pull the Connector Board from the front of the Control housing.
Exchanging the Connector Board: . from the Connector Board (see diagram).24 socket through its recess in the Control housing.Push the V. . P2. .Disconnect the ribbon cable connector.

the Id. (08669) 31-O Kundendienst
SERVICE MANUAL TNC 151 Page 47 Section 3.
EPROMs.
.The EPROM package direction as the .Memory Board .PLC Software No..-Nos. remove EPROM with extraction tool and place onto MOS protection mat. ' NC Software No. observe the to last digit of the hexa-decimal counting index must point ICs on the board. . JOHANNES HElDENHAlN GmbH D-8225 Traunreut ‘Tel.Visually respective check if sockets
the EPROMs are contacting after an exchange. NO. The machine parameters and any stored user-program are therefore erased! For continued operation. reentered into memory.When exchanging number (second EPROM Id. the machine parameters have to be
.HEIDENHAIN
DR. No. The description plate for the software numbers is found-on the rear of-the Control under the type-plate.Main Processor Board . the NC and PLC software have to be chansed.-
o Push screwdriver blade carefully between EPROM and socket.3 .CLP Processor Board have to be removed~from Thereto.
their
.
keys and press above and lay onto
MOS
Id.After the software exchanqe has been concluded. of
Software
Exchanae When exchanging the protection procedures! Control mounting software observe the MOS
Caution:
o The cover of the the 5 cross-head
can be removed after screws (top side) the following 2 3 4 the assembled boards
unscrewing
o To exchange the program. o Insert Important: EPROM into appropriate socket using insertion tool.
position programed manner) in the same The RAM &mory of the Memory Board is unbuffered diving the EPROM (software) exchange.. protection
Control
lift the board ejector pull out board from mat. outwards.

Transaction Requested loan 01 of request. The only charges to the customer in this case are for the repair of his own unit.4 Units Loan. provided that the our stock. for the duration of a repair carried out at HEIDENHAIN Traunreut or by an official HEIDENHAIN agent.
3.4 Replacement Units Replacement Parts
Parts. and names of all parts available for the TNC 151.
. However. unit should be returned to DR. Service Snits as possible. The list on page 49 shows the Id. These parts can be ordered from the department Kundendienst (Customer Service) at HEIDENHAIN Traunreut. Exchange units An exchange unit can be requested for a unit that is returned for repair.3). to give (i) the Id. when ordering. It is of utmost importance. in German. Nos. 14 days of receiving the exchange date unit JOHANNES unit. it is strongly recommended that all repairs and maintenance work are entrusted to an official HEIDENHAIN agency. Exchange. or the is available from A customer's faulty HEIDENRAIN within exchange units are shipped on the following day.neluelunAllu
DR.
Loan units Loan units are available. JOHANNES HEIDENHAIN GmbH for repairs undertaken by anyone else. Telexed order should be sent to the Kundendienst Telex: 17 866 982 or Teletex 866 982. (08669) 31-O
SERVICE MANUAL TNC 151 Page 48 Se&ion 3.Tel. JOHANNES HEIDENHAIN at non-repeatable discount prices. (ii) the name. JOHANNES D-8225Traunreut Kundendienst HEIDENHAIN GmbH . The only charges to the customer are the shipping charges. and (iii) the quantity of each part required.. This exchange unit is equipped with the latest hardware and software issue and is externally in excellent condition. replacement parts are available for all sub-assemblies discernible from the wiring diagrams (see section 4. free of charge.
Service units Service units are new units which are used for service purposes and can be obtained from DR.
Loan/Exchange/Service
TNC 151
In order to keeep machine down-time as short HEIDENHAIN offers a loan and exchange Senh3?. No responsibility can be accepted by DR.
In general. No.

has the keypads -32. bus is extended to 20-bit by a memory
b) TNC 151 E-Versions: The inputs and outputs are loaded on external PLC I/O-board (e. JOHANNES HElDENHAlN D-8225Traunreut.ically separated inputs (EO to E23) -6O.g. programmable outputs + emergency-stop protected against overload.1-
task of driving the on the front plate. . On the PLC interface board this 12V voltage is transformed in a 5V voltage for its TTL modules.or by the CLP processor -4o-.neIurlunAllu
DR.2on the main processor board can be accessed either by the main processor -3O.2-. . Thus a higher noise immunity is obtained.and are converted from the TTL level (5V) to the MOS level (12V) by means of a level converter -61-.and are led to the main processor via CRUIN.1
. On the PLC interface board either CRUIN 1 or CRUIN 2 are selected -64. .Tel. machine parameters stances) the PLC program are programmed in RAMS -20. an external processor. . These RAMS also serve as register file memory for the main processor -3o-. Protective resistances should never be replaced with normal resistances! The Analogue outputs are led via LC-filter -81. programmable outputs + 5 bipolar outputs and emergency stop protected against overload.
.The 16-bit address mapper -31-. The outputs (each having its own current supervision -El-) are transferred via line drivers to the machine interface. If 2 PLC I/O boards are connected the inputs from the 2nd board are multiplexed on CRUIN 2.I/O-Functions: a) TNC 151 A-Versions: 24 galvaf.(08669)31-0 Kundsndienst GmbH
SERVICE MANUAL TNC 151 Page 51 Se&ion 4. The intended coordinates. The serial CRU OUT signal is converted in 31 outputs via a serial-parallel-converter -El. All lines of this bus as well as the required addresses are galvanically separated by the optocouplers -6O.l-. .and 24 floating relay contact outputs (A0 to A22 + emergency stop) -61. programmed feed. display texts etc.1-.as protection against the oscillation of analogue outputs.via the PIG interface board. This interface is used to exchange data by means of a magnetic tape unit (ME) or.mounted discretely processor board.on the SE Board. respectively.1-.The keyboard controller LEDs and scanning the
-32. The input E63 is used to indicate an overloaded output to the main processor -3O-.
.The PLC program contained in IC-P9 -33. On the PlC I/O board a 12V voltage is generated by an external 24V supply.
.located on the PLC I/O board are multiplexed on CRUIN 1 line. The inputs and outputs are protected on the terminal board (A version) by special protective resistances 5. PL 1lOB: 26 unipolar.The main processor is connected with V.The RAMS -30.If the current supervision detects overcurrent no emergency-stop results in the standard PLC program. processed by the on the main are stored in a
. PL 100B: 31 unipolar.An overloaded output only switches off during the period of the overload. can therefore be transferred.lk ohms -8O. PL 1OOB or. The input and output states 4k x 1 PLC-RAM -33. Under the control of CRU addresses 63 programmable inputs (EO to E62) -E2. PL 100B) which are driven by the main processor -3O. and (under certain circmUser programs.1is '1-bit-PLC-processor" -33. The data is serially transferred via the CRU-bus.and 47 ohms -80. respectively.24 interface -34via a (serial) CRU-bus.

the programmed intended position .the distance of the intended position (influence on deceleration ramp) .
.g. The gate arrays are especially developed LSI circuits consisting of different gates and counters in which the direction of the movement and the number of pulses are calculated.the setting* of the override end feed potentiometer The calculating speed requires a wait-free RAM -40.
on the CLP processor/graphic
.the fast traverse rate* determined per machine parameter .1
CLP Processor/Graphic .and are also processed by the CLP processor. and Z-axis and an analog board TTL. supervised and converted in TTL signals.and -6O-.and then subdivided -5O. Y-. the on-to-off ratio and the amplitude of the system signals are constantly controlled by a supervision circuit -5O-. 90 degrees and RI signals are then led to the gate arrays -42.the programed feed rate .1.If the distance between the control and measuring system is more then 2010. subdivided. (08669) 31-O Kundendienst
SERVICE MANUAL TNC 151 Paae 52
section 4. . The signal lines are connected with the analog board via the PLC I/O board and the PLC interface board.The symmetry. The input amplifiers and the wiring for the signal subdivision are replaced with line receivers -5O. an EXE has to be interposed. An "R" version of the control is used accordingly (e.If instead of linear position transducers incremental encoders are used to ascertain actual values a reference pulse appears once per revolution. .on this analog board whose outputs are directly connected to the gate arrays -42. The level conversion MOS/TTL as well as the galvanic decoupling is carried out on the PLC interface boards via -61. IV are inhibited on the analog board -5O-.of the CLP processor board.Operating system is contained (32k x 8).The signals from the handwheel (if present) are shaped via the functional block -53.to ascertain the actual values of the axes.as on the "normal' (sine) analog board.and transferred to the CLP processor board. Y. Since only one reference pulse is to be evaluated all other reference pulses of the axes X.by delaying (phase shifted) and combining them differently.the instantaneous actual positions .on the CLP processor board.Primarily
Unit: board. The signals of the handwheel are likewise processed -53.The main task is the calculation of the instantaneously intended values of the analog output voltages dependent on: .2-.1-
. The measuring signals are thus already amplified.The measuring system signals are processed on the analog board. Z. The supervision signal of the EXE is also buffered -5O. evaluated.
.
in EPROM IC-P3 -40. TNC 155 AR) equipped with a combined EXE connection for X-. The subdivided 0 degree. These signals are amplified at first -50.ncIlJelunAll\
DR JOHANNES HEIDENHAIN GmbH D-8225 Traunreut ‘Tel. . This information can then be scanned by CLP processor -4O.

1(digital-analog-converter). These must be triggered separately once every 5ms by the CLP processor -4O.g. Z-. IV. and an 11V
.Tel.ll~lUEN~iilN
DR.(O8669)31&0
SERVICE MANUAL TNC 151 Page 53 Section 4. respectively. (start/stop pulse e.
.) .4.2so that the data are transferred to the shift register -41.The drive of the screen is another important task of the TNC 151 CLP processor. the feed potentiometer. Thus signal can be inverted by means of an exclusive-or-gate -41.On the SE-board (or the PLC interface board) the V. JOHANNES HEIDENHAIN GmbH
D-8225
Kundendienrt
Traunreut
. The digital output values calculated for all axes are multiplexed on the CRU OUT line and are converted in a 12 bit parallel format on the analog board.1 signal.On the analog board the buffer battery (-3. The X-.and S-analog values generated shortly one after the other at the output of the DAC are allocated to the single axes by means of five sample and hold circuits -52.are on the analog board.24 signals of the handwheel unit HE 310 are connected to the line drivers or. an emergency-stop signal is triggered.46V) and the internal temperature (65O) of the control are also supervised -51-. These voltages are compared with the adjusted values of the override and feed potentiometers -52.3. It only has to write the texts to be displayed into the CRT RAM -41-l-.Two "watch dog" monoflops -51.and are led to the terminal board. The five individual analog voltages are amplified and buffered subsequently -52.3. A serial interface module -43.in the right sequence. These successive digital values are then converted in analog values (voltages) by means of a DAC -52.to generate an inverse video display.2-. .and once every 2Oms by the main processor -3o-.The data of the CLP processor is transferred to the analog outputs via the serial CRU bus.and the results are transmitted to the CLP processor via CRUIN. If the monoflops are not driven within 5ms or 2Dms (error state). A special CRT controller TMS 9937 -41. signals the screen. the bright/dark
. .on the CLP/graphic board stands between line receivers/drivers and the CLP processor to transfer data with the handwheel unit and to format data. The video signal. The supervision signals are led to the CLP processor via the CRUIN line.generates the necessary addresses for the CRT RAM and the character generator IC-P19 -41. supply the horizontal/vertical are used to operate sync.1.The signals of the 3D-probe are buffered via the 3Dprobe-interface on the SE-board (or the PLC interface board) -63. respectively. to the line receivers -62-.and are evaluated via the counter module -42.on the CLP processor/graphic board. The output voltages can thus be adapted to the values adjusted by the override or. . Y-.

JOHANNES D-8225Traunreut Kundendienst HEIDENHAIN GmbH .
.The +12V supply voltage for the V. If U2 (+5V) exceeds if there is a failure the overvoltage recognition -73. moreover.(O8669)31-0
SERVICE MANUAL TNC 151 Page 54 Se&ion 4.is immediately effective and causes the overvoltage protection (thyristor) -73.this protective measure.+llV are generated via the forward converter -70. The flyback regulator -7O.+5V are converter coupled operation
generated for the TTL modules via the forward -7O-.01and -70. The switch regulator -70. A greater damage at the subsequent electronics is thus inhibited by means of.triggering a reset signal if the power supply is interrupted or if the supply voltage drops below a predetermined minimum level (167V if set for 220V operation) for a short time. .linductively with the flow converter generates +/-15V for the amplifier.24 interface with the help of the +15V by means of a linear
-70.
. a voltage supervision -72.3for the TNC 151 (BE 111. start -71limits the relatively high switch-on
. Thus Ul is short-circuited coming directly from the power supply transformer -74.Tel.31readjust the output voltage load controlled. BE 211) screen which in contrast to the TNC 155 (BE 411) screen does not have an own power supply unit.1to connect through.On the power supply board there is. is generated regulator
.2-.via the rectifier -75-.1
Power
Supply
unit
.The soft current.nellJel\nAll\
DR.